Plastic container with open sides and locking features

ABSTRACT

A plastic box includes a top and a tray that may be locked together. The top has two open sides to save material. The top can have drain holes along its edges, and the tray likewise has drain holes along its edges, so that when the tray of one container is stacked on the top of another container, water in the top container can drain down and through the bottom container.

I. FIELD OF THE INVENTION

The present invention relates generally to plastic containers.

II. BACKGROUND OF THE INVENTION

Plastic boxes are used for a wide variety of applications. By way of non-limiting example, half-slotted plastic containers can be used for transporting vegetables such as asparagus. So-called design style trays can also be used for carrying goods.

Regardless of the type or purpose, a plastic container ordinarily is made from a flat substrate, with the panels of what will become the container being established by appropriately forming fold lines and flap cuts in the substrate. To render the substrate into a three-dimensional container, the substrate is folded along the fold lines, the flap cuts are used as appropriate to overlay one panel on another, and so on.

As recognized herein, it is desirable to minimize the amount of plastic used in the container, to conserve costs. It is also desirable under some circumstances to more firmly engage a top of a container with the tray of the container than merely by an interference fit between the two container components. Furthermore, recognizing that the tray of one container is often stacked on the top of another container, it is desirable to provide a way for water to drain through the containers without weakening the bottom of the trays. It is still further desirable to provide a container with good ventilation for storing, e.g., certain vegetables such as asparagus. With these critical recognitions in mind, the various embodiments herein are provided.

SUMMARY OF THE INVENTION

A container includes a first substrate configured with fold lines and cut lines and is folded along at least some of the lines to form a parallelepiped-shaped hollow top. The top has opposed closed walls and opposed open walls orthogonal to the closed walls, to conserve material.

In preferred implementations a second substrate is configured with fold lines and cut lines and is folded along at least some of the lines to form a parallelepiped-shaped hollow tray, with the top and tray engaging in an interference fit to form a closure. The top can be formed with at least one drain hole along at least one top edge and the tray can be formed with at least one drain hole along at least one bottom edge, and a drain hole of the top is registered with a drain hole of the tray when a tray of one container is stacked on the top of another container.

If desired, the top can define a top surface that is formed with a matrix of holes inboard of top edges. The holes may be racetrack-shaped. A tab can extend upwardly from the drain hole in the top edge and can be configured to engage the drain hole of a tray positioned on the top.

In some implementations, a tray lock element is foldable outwardly away from one the closed walls of the top, with a portion of the tray lock element extending beyond and being foldable around a bottom periphery of the top for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery. In other implementations, a top lock element is foldable outwardly away from the tray and can engage a receptacle in one of the open walls of the top when the tray is juxtaposed with a bottom periphery of the top. In still other implementations, a top lock element is foldable outwardly away from the tray for engaging a receptacle in one of the closed walls of the top when the tray is juxtaposed with a bottom periphery of the top.

In another aspect, a container includes a first substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow top and a second substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow tray. The top can be formed with a drain hole along a top edge and the tray can be formed with a drain hole along a bottom edge. A drain hole of the top is registered with a drain hole of the tray when a tray of one container is stacked on the top of another container.

In still another aspect, a container includes a first substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow top, and a second substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow tray. A tray lock element is foldable outwardly away from a wall of the top. A portion of the tray lock element extends beyond and is foldable around a bottom periphery of the top for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery.

The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a substrate that can be rendered into a first non-limiting plastic box top portion, showing a wrap-lock structure;

FIG. 2 is a plan view of a substrate that can be rendered into a first non-limiting plastic box tray portion, showing a wrap-lock receiving structure;

FIG. 3 is a perspective view of the substrates shown in FIGS. 1 and 2 in an exploded relationship after being rendered into their container shapes;

FIG. 4 is a plan view of a substrate that can be rendered into a second non-limiting plastic box top portion, showing a side lock structure;

FIG. 5 is a plan view of a substrate that can be rendered into a second non-limiting plastic box tray portion, showing a side lock receiving structure;

FIG. 6 is a plan view of a substrate that can be rendered into a third non-limiting plastic box top portion, showing an end lock structure;

FIG. 7 is a plan view of a substrate that can be rendered into a third non-limiting plastic box tray portion, showing an end lock receiving structure;

FIG. 8 is a plan view of a substrate that can be rendered into a fourth non-limiting plastic box top portion, with no lock structure;

FIG. 9 is a plan view of a substrate that can be rendered into a fourth non-limiting plastic box tray portion, with no lock receiving structure; and

FIG. 10 is a plan view of a substrate that can be rendered into a fifth non-limiting plastic box top portion, with vented ends.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIGS. 1-3, a container is shown, generally designated 10, that is rendered from a flat top substrate 12 (FIG. 1) that may have a honeycomb (cardboard-like) construction and a flat tray substrate 14 (FIG. 2) that may also have a honeycomb construction. The substrates 12, 14 preferably are made (e.g., by extrusion) of a plastic such as polypropylene or polyethylene. While the present invention is broadly directed to many types of containers, FIGS. 1-3 illustrate a container that may be used for carrying wet articles such as vegetable bags. Any dimensions shown in the drawings are non-limiting on the invention.

In accordance with principles known in the art, the substrate 12 is a single piece of plastic that is formed with plural fold lines 16 that demarcate the creases between adjacent panels about which the panels can be folded. Also, the substrate 12 as shown may be formed with plural cuts 18 between adjacent flaps each of which cuts 18 physically separates its adjacent flaps along the length of the cut. Cuts are also formed to define locking structure as more fully set forth below. The substrate 12 is folded along the fold lines 16 until adjoining panels are perpendicular to each other, with the fold lines 16 establishing the edge between adjacent panels. Also, the flaps likewise are moved owing to the freedom of movement afforded by the cuts 18 to render the substrate 12 into the container top 22 shown in FIG. 3 wherein a substantially paralellepiped-shaped interior chamber is formed. The substrate 14 likewise may be folded and moved about fold lines and cuts to establish the parallelepiped-shaped tray 24 shown in FIG. 3.

Because FIGS. 1-3 have many features in common with the embodiments shown in FIGS. 4-10, attention is first directed to the common features. Starting with the top 22, a top panel 30 is formed with a matrix of holes 32 as shown. In non-limiting embodiments the holes 32 are racetrack-shaped as shown, and the non-limiting matrix has seven columns and nine rows of holes 32, with adjacent rows being staggered from each other and with adjacent columns being staggered from each other as shown.

Depending down orthogonally from the ends of the top panel 30 are opposed end panels 34, each of which forms a substantially complete and continuous surface from the top panel 30 to the bottom periphery 36 of the top 22 except for cuts and folds defining the locking element more fully described below which is unique to the embodiment of FIGS. 1-3. Drainage cuts 38 (FIG. 1) can be formed in the fold lines between the top panel 30 and the end panels 34, so that when the substrate 12 is folded, tabs 40 pull away from surrounding material to form drain holes 42 (FIG. 3) in the edges between the top panel 30 and end panels 34, for purposes to be shortly disclosed. The tabs 40 may extend above the top panel 30 as shown, and may define generally semi-circular peripheries as also shown. While tabs 40 and associated drain holes 42 are shown in the top edges between the end panels 34 and top panel 30, only one or more than two of the top edges may be formed with drain holes.

Still referring to FIGS. 1-3, side panels 44 are folded about fold lines to the orthogonal orientation they bear with the top panel 30 as shown in FIG. 3. Unlike the end panels 34, however, the side panels 44 do not extend completely to the bottom periphery of the top 22 as shown, but instead extend only part way to the bottom periphery, rendering the top 22 that has opposed open side walls which are orthogonal to the closed end wall established by the end panels 34. In this way, plastic material is conserved. In some implementations, vent holes 45 may be formed in a line near the top of each end panel 34 and each side panel 44 as shown.

To further conserve plastic, small semicircular cut-outs 46 can be formed in the bottom periphery of the top 22 as shown.

With the combination of structure shown in FIGS. 1-3, it may now be appreciated that in addition to other noted advantages the container has good ventilation for storing, e.g., certain vegetables such as asparagus that require well-ventilated containers.

Completing the description of the structure that can be generally common to all embodiments, end flaps 48 can be folded about fold lines to be orthogonal to the end panels 34, extending down from the top panel 30 to the bottom periphery of the top 22 but not extending all the way across to the opposite end flap. Thus, the open sides of the top 22 are closed completely along the top edge by the side panels 44 and completely along their left and right edges by the end flaps 48, but are open in the area that is between the inside edges of the end flaps 48, the bottom periphery of the top 22, and the bottom edge of the side panel 44.

Locking tab cut lines are made between each end flap 48 and its contiguous side panel 44 as shown to establish a locking tab 50 on each side panel 44. A locking tab may be, without limitation, generally octagonal-shaped. Also, locking receptacle cut lines are made between each end flap 48 and its contiguous end panel 34 to establish tab receptacles 52 in the edges that are formed by the fold lines between each end panel 34 and its adjoining end flaps 48. When the substrate 12 of FIG. 1 is folded into the top 22 of FIG. 3, each locking tab 50 is closely received into the closest tab receptacle 52 to hold the top 22 in the configuration shown.

Completing the description of the structure of the top 22 by drawing attention to a feature that is not shared by the other embodiments of FIGS. 4-9, in at least one of the end panels 34, a tray lock element 54 is established by cut lines 56 that form three sides of a rectangle and by two parallel closely spaced lock fold lines 58 forming the fourth side of the rectangle. A hole 60 can be formed in the lock element 54 if desired. The free end of the lock element 54 is formed, using cut lines and fold lines, with a lock tab 62, and the lock tab 62 can be pivoted about an interior fold line 64. With this structure, the tray lock element 54 can be folded outwardly away from the closed wall of the top 22 and is sized and positioned on the wall such that a portion of the lock element extends beyond and can be folded around the bottom periphery of the top, for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery as more fully set forth below.

Now considering the substrate 14/tray 24 shown in FIGS. 2 and 3 and first explaining features that can be common to all embodiments if desired, the tray 24 may have a continuous bottom panel 66 as shown that is substantially continuous and complete from edge to edge of the bottom panel 66, except for drain holes 68 that may be formed in one or more edges (drain holes 68 are formed in all four edges in the non-limiting embodiment shown in FIGS. 2 and 3). Because the bottom panel 66 is continuous throughout, it is relatively strong.

On each end of the bottom panel 66 are over-folded end panels 70, 72 between which are double fold lines 74. Also, straddling each set of end panels 70, 72 are opposed end flaps 76. The substrate 14 is folded with the end flaps 76 sandwiched tightly between the end panels 70, 72 as can be appreciated looking at FIG. 3, with the resulting layered end structure consisting of panels 70, 72 and flap 76 being oriented orthogonal to the bottom panel 66.

As best shown in FIG. 2, the drain holes 68 that are formed in the edge between the bottom panel 66 and each layered end structure may be semi-circular in shape in the end structure and rectilinear in shape in the bottom panel 66. Holding tabs 77 are formed on the free edge of the outer (in FIG. 2) end panel 72, and the holding tabs 77 engage the complementarily-shaped rectilinear portions of the drain holes 68 that are formed in the edge between the bottom panel 66 and each layered end structure to hold the tray 24 in the configuration shown in FIG. 3.

Opposed side panels 78 bound the remaining two sides of the bottom panel 66. As best shown in FIG. 2, the drain holes 68 that are formed in the edge between the bottom panel 66 and each side panel 78 may have a variety of shapes, including generally trapezoidal and racetrack shaped. Opposite ends of each side panel 78 are connected at fold lines to respective end flaps 76, so that with the end flaps 76 locked between the end panels 70, 72, the side panels 78 are held in the configuration shown in FIG. 3.

In the specific embodiment shown in FIGS. 2 and 3, also formed in the edge between the bottom panel 66 and each layered end structure and substantially intermediate the drain holes in the edge are lock receptacles 80. The lock receptacles 80 receive respective tray locking elements 54 in the top 22, which recall extend beyond and wrap around the bottom periphery of the top 22, to hold the top 22 onto the tray 24. The bottom periphery of the top 22 fits snugly within the panels of the tray 24, resting on the bottom panel 66.

With the above structure and with specific reference to FIG. 3, it can now be appreciated that if the tray 24 of one container is stacked on the top 22 of another container, the drain holes that are formed in the edge between the bottom panel 66 and each layered end structure of the tray are registered with the drain holes 42 of the top 22 by means of the tabs 40. In this way, liquid advantageously can drain from the top to the bottom of a stack of containers, without weakening the bottom panels 66 of the trays 24 by forming drain holes inboard of the edges of the bottom panels 66.

FIGS. 4 and 5 show a top substrate 84 and a tray substrate 86 that are configured substantially identically to the substrates 12, 14 shown in FIGS. 1 and 2, except that instead of a wrap-around locking structure 54, 80, the top substrate 84 is formed with lock receptacles 88 in each end flap 90, and the tray substrate 86 is formed with two pivotable lock elements 92 in each side panel 94, with the lock elements 92 engaging the lock receptacles 88 to hold the top onto the tray.

FIGS. 6 and 7 show a top substrate 96 and a tray substrate 98 that are configured substantially identically to the substrates 12, 14 shown in FIGS. 1 and 2, except that instead of a wrap-around locking structure 54, 80, the top substrate 96 is formed with lock receptacles 100 in each end panel 102, and the tray substrate 98 is formed with two pivotable lock elements 104 in each layered end structure 106, with the lock elements 104 engaging the lock receptacles 100 to hold the top onto the tray.

FIGS. 8 and 9 show a top substrate 108 and a tray substrate 110 that are configured substantially identically to the substrates 12, 14 shown in FIGS. 1 and 2, except that no tray-top locking structure is provided.

FIG. 10 shows a top substrate 112 that is configured substantially identically to the substrate 12 shown in FIG. 1, except that no tray locking structure is provided and an enlarged rectangular vent window 114 is formed in each end panel 116.

While the particular PLASTIC CONTAINER WITH OPEN SIDES AND LOCKING FEATURES as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and is thus representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more”. For instance, the above-described lock elements and lock receptacles may be reversed from tray to top and vice-versa. It is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. Absent express definitions herein, claim terms are to be given all ordinary and accustomed meanings that are not irreconcilable with the present specification and file history. 

1. A container comprising: a first substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow top, the top having opposed closed walls and opposed open walls orthogonal to the closed walls.
 2. The container of claim 1, further comprising a second substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow tray, the top and tray engaging in an interference fit to form a closure.
 3. The container of claim 2, wherein the top is formed with at least one drain hole along at least one top edge and the tray is formed with at least one drain hole along at least one bottom edge, a drain hole of the top being registered with a drain hole of the tray when a tray of one container is stacked on the top of another container.
 4. The container of claim 3, wherein the top defines a top surface formed with a matrix of holes inboard of top edges.
 5. The container of claim 3, wherein the holes are racetrack-shaped.
 6. The container of claim 3, comprising a tab extending upwardly from the drain hole in the top edge and configured to engage the drain hole of a tray positioned on the top.
 7. The container of claim 2, comprising at least one tray lock element foldable outwardly away from one the closed walls of the top, a portion of the tray lock element extending beyond and being foldable around a bottom periphery of the top for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery.
 8. The container of claim 2, comprising at least one top lock element foldable outwardly away from the tray and engaging a receptacle in one of the open walls of the top when the tray is juxtaposed with a bottom periphery of the top.
 9. The container of claim 7, further comprising at least one top lock element foldable outwardly away from the tray and engaging a receptacle in one of the closed walls of the top when the tray is juxtaposed with a bottom periphery of the top.
 10. A container comprising: a first substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow top; and a second substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow tray, wherein the top is formed with at least one drain hole along at least one top edge and the tray is formed with at least one drain hole along at least one bottom edge, a drain hole of the top being registered with a drain hole of the tray when a tray of one container is stacked on the top of another container.
 11. The container of claim 10, wherein the top has opposed closed walls and opposed open walls orthogonal to the closed walls.
 12. The container of claim 10, wherein the top defines a top surface formed with a matrix of holes inboard of top edges.
 13. The container of claim 10, comprising a tab extending upwardly from the drain hole in the top edge and configured to engage the drain hole of a tray positioned on the top.
 14. The container of claim 11, comprising at least one tray lock element foldable outwardly away from one the closed walls of the top, a portion of the tray lock element extending beyond and being foldable around a bottom periphery of the top for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery.
 15. The container of claim 11, comprising at least one top lock element foldable outwardly away from the tray and engaging a receptacle in one of the open walls of the top when the tray is juxtaposed with a bottom periphery of the top.
 16. The container of claim 11, further comprising at least one top lock element foldable outwardly away from the tray and engaging a receptacle in one of the closed walls of the top when the tray is juxtaposed with a bottom periphery of the top.
 17. A container comprising: a first substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow top; a second substrate configured with fold lines and cut lines and folded along at least some of the lines to form a parallelepiped-shaped hollow tray; at least one tray lock element foldable outwardly away from a wall of the top, a portion of the tray lock element extending beyond and being foldable around a bottom periphery of the top for engaging a lock receptacle of the tray when the tray is juxtaposed with the bottom periphery.
 18. The container of claim 17, wherein the top is formed with at least one drain hole along at least one top edge and the tray is formed with at least one drain hole along at least one bottom edge, a drain hole of the top being registered with a drain hole of the tray when a tray of one container is stacked on the top of another container.
 19. The container of claim 17, wherein the top has opposed closed walls and opposed open walls orthogonal to the closed walls. 